04 Liner

Cylinder Liner & jacket- 2 stroke engine
The structure above frame is called

cyl. Block / entablature or jacket.
Generally box form-2 stroke engine
Cylinder liner is attached to jacket.
Space between liner and block forms
water space.
Liner flanged on top rests on
shoulder of cyl. block, cyl. head is
bolted to block. Joint between liner and
head is made gas tight by gasket or by
accurate metal to metal fit.
Material - pearlitic gray cast iron –
contains vanadium and titanium – to
refine structure,give strength and
increase wear resistance, reducing
corrosion.
For lubrication, holes are provided
and connected to lubricator.
liner
Material.
Cast iron is generally regarded as a suitable
material for construction of diesel engine
cylinder liner. In order to improve strength and
induce specific desirable properties such as
strength and surface properties, cast iron is
alloyed with the inclusion of small quantities of
nickel, chromium, molybdenum, vanadium,
copper etc. Such inclusions refine the grain
structure of the material.
Good quality ‘Pearlitic Grey Cast Iron’
consist of the following alloying
material:
Carbon: 3 to 3.4%. Its graphite flakes assist
lubrication.
Silicon: 1 to 2.0%. Improves fluidity and
graphite formation.
Manganese: 0.6 - 0.8%
Phosphorous: 0.5% maximum. Reduces
porosity
Vanadium: 0.15%. Refines grain structure
Titanium: 0.05%. Improves strength
Reasons for using Cast Iron:
Can be cast in to intricate shapes.
Has good wear resistance:
Due to semi-porous surface holding oil pockets.
Possesses good thermal conductivity.
Damps out vibrations due to rapid combustion.
Cheap material.
The cylinder liner forms the cylindrical
space in which the piston reciprocates. The
reasons for manufacturing the liner
separately from the cylinder block (jacket) in
which it is located are as follows;
The liner can be manufactured using a
superior material to the cylinder block. While
the cylinder block is made from a grey cast
iron, the liner is manufactured from a cast
iron alloyed with chromium, vanadium and
molybdenum. (cast iron contains graphite, a
lubricant. The alloying elements help resist
corrosion and improve the wear resistance
at high temperatures.)
.
The cylinder liner will wear with use, and
therefore may have to be replaced. The cylinder
jacket lasts the life of the engine.
At working temperature, the liner is a lot hotter

than the jacket. The liner will expand more and
is free to expand diametrically and lengthwise.
. The Liner will get tend to get very hot during

engine operation as the heat energy from the
burning fuel is transferred to the cylinder wall. So
that the temperature can be kept within
acceptable limits the liner is cooled
• The liner must be gauged regularly to
establish the wear rate and check that it is
within manufacturers tolerances.
• Excessive wear is caused by lack of
lubrication, impurities in fuel air or
Lubricating oil, bad combustion and acid
attack.
• Max wear is 1% of the diameter. Liner
wears @ 0.1mm/1000 hrs
Necessity of Bore Cooling Design
To increase the power of the engine for a given
number of cylinders, either the efficiency of the
engine must be increased or more fuel must be
burnt per cycle.
To burn more fuel, the volume of the combustion
space must be increased, and the mass of air for
combustion must be increased.
Because of the resulting higher pressures in the
cylinder from the combustion of this greater
mass of fuel, and the larger diameters, the liner
must be made thicker at the top to
accommodate the higher hoop stresses, and
prevent cracking of the material.
If the thickness of the material is increased,
then it stands to reason that the working
surface of the liner is going to increase in
temperature because the cooling water is
now further away.
Increased surface temperature means that
the material strength is reduced, and the
oil film burnt away, resulting in excessive
wear and increased thermal stressing.
On some large bore, long stroke engines it was
found that the undercooling further down the
liner was taking place.
Why is this a problem?
Well, the hydrogen in the fuel combines with the
oxygen and burns to form water.
Normally this is in the form of steam, but if it is
cooled it will condense on the liner surface and
wash away the lube oil film.
Fuels also contain sulphur.
This burns in the oxygen and the products
combine with the water to form sulphuric acid.
If this condenses on the liner surface (below 140º)
then corrosion can take place.
Once the oil film has been destroyed then wear will
take place at an alarming rate.
One solution is to insulate the outside of the liner
so that there was a reduction in the cooling
effect.
On The latest engines the liner is only cooled at
the very top.
Cylinder lubrication: Because the cylinder is
separate from the crankcase there is no splash
lubrication as on a trunk piston engine.
Oil is supplied through drillings in the liner.
Grooves machined in the liner from the injection
points spread the oil circumferentially around the
liner and the piston rings assist in spreading the oil
up and down the length of the liner.
The oil is of a high alkalinity which combats the acid
attack from the sulphur in the fuel.
The latest engines time the injection of oil using a
computer which has inputs from the crankshaft
position, engine load and engine speed. The
correct quantity of oil can be injected by opening
valves from a pressurized system, just as the
piston ring pack is passing the injection point.
Cylinder Lubrication
• In this photo of a Sulzer RND liner the lubricators are

positioned near the top of the liner.
• Maintaining an oil film of adequate thickness and
oil refreshment rate is also an important
consideration when determining the position of
lubrication points. Adequate thickness of lube oil
is necessary to prevent metal to metal contact
between ring and liner, and an adequate
refreshment rate is necessary to combat acid
attack.
• Lubricating quills may have to pass
through the cylinder liner cooling space.
These are known as “wet quills”.
• To prevent water leakage into the liner or
oil leakage into the water space where it
would form an insulating layer on the
outside surface of the liner, an outer tube
with ‘0’ ring seals is fitted.
The Jensen SIP Lubricator
Jensen Swirl Injection Principle
• The cylinder lubricator pumps
the oil to the SIP valves
mounted in the cylinder liner
wall. The valves (see also
below) are equipped with a
nozzle for spraying tiny
droplets of cylinder oil
tangentially to the liner wall,
covering a large area above
the next injection valve.
Spraying from all valves
ensures covering the entire
circumference of the cylinder
liner.
Gauging a Liner
• As mentioned earlier, cylinder liners will
wear in service. Correct operation of the
engine (not overloading, maintaining
correct operating temperatures) and
using the correct grade and quantity of
cylinder oil will all help to extend the life
of a cylinder liner. Wear rates vary, but
as a general rule, for a large bore engine
a wear rate of 0.05 - 0.1mm/1000 hours
is acceptable. The liner should be
replaced as the wear approaches 0.8 -
1% of liner diameter. The liner is gauged
at regular intervals to ascertain the wear
rate.
• It has been known for ships to go for
scrap after 20 + years of operation with
some of the original liners in the engine.
• Because of the action of the
piston rings, the varying gas
pressure and temperature in
the cylinder, the wear will not
be even down the length of
the liner.
• Consider the piston just
beginning the power stroke.
The gas pressure pushing
the piston rings against the
liner wall is at its highest;
The liner surface
temperature up at this part of
the liner is about 200°C, so
the viscosity of the
lubricating oil is low.
The relative speed of the piston is low, and so the
lubrication is only boundary.
Because of these factors wear at the top of a liner
increases to a maximum a few centimetres
below the position of the top ring at TDC, and
then decreases as the ring pressure and liner
wall temperature decreases and the piston
speed increases building up a hydrodynamic film
between liner and ring surfaces.
Then as the piston slows down and the rings pass
over the port bars, the wear will increase due to
boundary lubrication, a reduction in surface
area, and oil being blown out into the scavenge
space.

04 Liner

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What are the main components of a cylinder liner?

What materials are used to make cylinder liners and why?

Cylinder Liner & jacket- 2 stroke engine

The structure above frame is called

Can be cast in to intricate shapes.

Has good wear resistance:

Due to semi-porous surface holding oil pockets.

Possesses good thermal conductivity.

Damps out vibrations due to rapid combustion.

At working temperature, the liner is a lot hotter

. The Liner will get tend to get very hot during

• In this photo of a Sulzer RND liner the lubricators are

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